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SERVICE STATION MANUALB043109

Engine V750 IE MIU G3

SERVICE STATIONMANUAL

Engine V750 IE MIU G3

THE VALUE OF SERVICEAs a result of continuous updates and specific technical training programmes for Moto Guzzi products,only Moto Guzzi Official Network mechanics know this vehicle fully and have the specific tools necessary

to carry out maintenance and repair operations correctly.The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before ridingit, its regular maintenance and the use of original Moto Guzzi spare parts only are essential factors!

For information on the nearest Official Dealer and/or Service Centre consult our website:www.motoguzzi.com

Only by requesting Moto Guzzi original spare parts can you be sure of purchasing products that weredeveloped and tested during the actual vehicle design stage. All Moto Guzzi original spare parts undergo

quality control procedures to guarantee reliability and durability.The descriptions and images in this publication are given for illustrative purposes only and are not binding.While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand,to make any changes to components, parts or accessories, which it considers necessary to improve the

product or which are required for manufacturing or construction reasons.Not all versions/models shown in this publication are available in all countries. The availability of individual

versions should be checked with the Official Moto Guzzi sales network.The Moto Guzzi brand is owned by Piaggio & C. S.p.A.

© Copyright 2012 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole orin part is prohibited.

Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italywww.piaggio.com

http://www.motoguzzi.com/

http://www.piaggio.com/

SERVICE STATION MANUALEngine V750 IE MIU G3

This manual provides the main information to carry out regular maintenance operations on your vehicle.This manual is intended to Moto Guzzi Dealers and their qualified mechanics; several concepts havebeen deliberately omitted as they are considered unnecessary. As it is not possible to include completemechanical notions in this manual, users should have basic mechanical knowledge or minimumknowledge about the procedures involved when repairing motorcycles. Without this knowledge, repairingor checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check proceduresare not described in detail, be extremely cautious so as not to damage components or injure individuals.In order to optimise customer satisfaction when using our vehicles, Moto Guzzi s.p.a. commits itself tocontinually improve its products and the relative documentation. The main technical modifications andchanges in repair procedures are communicated to all Moto Guzzi Sales Outlets and its InternationalSubsidiaries. These changes will be introduced in the subsequent editions of the manual. In case ofneed or further queries on repair and check procedures, consult Moto Guzzi CUSTOMERDEPARTMENT, which will be prepared to provide any information on the subject and any furthercommunications on updates and technical changes related to the vehicle.

NOTE Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personalinjury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicleto prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of seriousdamage to the vehicle and sometimes even the invalidity of the guarantee

INDEX OF TOPICS

CHARACTERISTICS CHAR

SPECIAL TOOLS S-TOOLS

ENGINE ENG

INDEX OF TOPICS

CHARACTERISTICS CHAR

Tightening Torques

Engine

CRANKCASEpos. Description Type Quantity Torque Notes

1 Column nuts - 4 42 Nm (30.98 lbf ft) -2 Nut M8x1.25 6 22 Nm (16.22 lbf ft) -3 TCEI screw M6x25 12 10 Nm (7.37 lbf ft) -4 Oil drainage plug M10x1 1 40 Nm (29.5 lbf ft) -- Spark plugs - 2 30 Nm (22.13 lbf ft) -

OPTION 01

Engine V750 IE MIU G3 Characteristics

CHAR - 7

TIMING SYSTEM COVERpos. Description Type Quantity Torque Notes

1 TCEI screw M6x25 10 10 Nm (7.37 lb ft) -2 TCEI screw M6x30 2 10 Nm (7.37 lb ft) -3 Alternator cover screws M6x35 5 10 Nm (7.37 lb ft) Loctite 243

OPTION 02

Characteristics Engine V750 IE MIU G3

CHAR - 8


1 TCEI screw M6.15x11 10 10 Nm (7.37 lb ft) Loct. 2432 TCEI screw M6.15x0.8 1 10 Nm (7.37 lb ft) Loct. 243

HEAD - CYLINDERpos. Description Type Quantity Torque Notes

1 Central stud bolt M8x143 2 20 Nm (14.75 lb ft) Loctite 5422 Short stud bolt M10x182 4 42 Nm (30.98 lb ft) -3 Long stud bolt M10x214 4 42 Nm (30.98 lb ft) -4 Nuts - pre-tightening M10x1.5 4 25 Nm (18.44 lb ft) -4 Nuts - tightening M10x1.5 4 42 Nm (30.98 lb ft) -5 Column nut - 4 25 Nm (18.44 lb ft) -6 Nut - 2 28 Nm (20.65 lb ft) -7 Internal Head cover screws M6x25 4 8-10 Nm (5.90-7.37 lb

ft)-

8 Outer head cover screws M6x52.5 8 8-10 Nm (5.90-7.37 lbft)

-


CHAR - 9

CRANKSHAFTpos. Description Type Quantity Torque Notes

1 Oil plug - 1 15 Nm (11.06 lbf ft) Loctite 6012 Connecting rod screws - 4 33 Nm (24.34 lbf ft) -3 Flywheel screws - 6 42 Nm (30.98 lbf ft) Loctite 243


CHAR - 10

TIMING SYSTEMpos. Description Type Quantity Torque Notes

1 Tone wheel screw M8x22 1 25 Nm (18.44 lb ft) -2 Timing system gear screws - 2 25 Nm (18.44 lb ft) Loctite 2433 Chain tensioner screw M6x16 1 10 Nm (7.38 lb ft) -4 Valve clearance adjuster screw M6x1 4 10 Nm (7.38 lb ft) -

OIL PUMPpos. Description Type Quantity Torque Notes

1 Transmitter joint - 1 25 Nm (18.44 lbf ft) -2 Oil pressure sensor - 1 30 Nm (22.13 lbf ft) -3 Oil pump screws M6x35 3 10 Nm (7.38 lbf ft) Loctite 6484 Oil filter screw - 1 6 Nm (4.43 lbf ft) -

OPTION 01


CHAR - 11

CLUTCH Ipos. Description Type Quantity Torque Notes

1 Crown screws M6x16 6 10 Nm (7.38 lb ft) Loctite 2432 Gearbox screws M8x35 5 25 Nm (18.44 lb ft) -3 Bearing block washers fixing screws TSEI 4 10 Nm (7.38 lb ft) Loct. 2434 Oil load cap - 1 25 Nm (18.44 lb ft) -5 Oil filter cap - 1 .. Nm (... lb ft) -6 Oil pump fixing screw Torx M5x16 1 6 Nm (4.42 lb ft) Loct. 2437 Gearbox fixing screws TCEI M6x55 14 10 Nm (7.38 lb ft) -


CHAR - 12

CLUTCH IIpos. Description Type Quantity Torque Notes

1 Clutch shaft nut - 1 100 Nm (73.76 lb ft) Loctite 243

OPTION 02


1 Crown screws M6x16 6 10 Nm (7.38 lb ft) Loctite 2432 Gearbox screws M8x35 5 25 Nm (18.44 lb ft) -3 Clutch belt cover screws M6x30 11 10 Nm (7.38 lb ft) Loctite 243


CHAR - 13



OPTION 01


CHAR - 14

GEARBOXpos. Description Type Quantity Torque Notes

1 Neutral sensor - 1 10 Nm (7.38 lb ft) -2 Plate fixing screw Torx M5x16 1 4 Nm (2.95 lb ft) Loct. 2433 Bearing block washers fixing screw TSEI 1 10 Nm (7.38 lb ft) Loct. 2434 Breather cap - 1 20 Nm (14.75 lb ft) -

OPTION 02


1 Neutral sensor - 1 8 Nm (5.90 lb ft) -2 Screws M6x14 4 10 Nm (7.38 lb ft) -3 Gearbox cover screws M6x30 5 10 Nm (7.38 lb ft) -4 Gearbox cover screws M6x35 2 10 Nm (7.38 lb ft) -5 Gearbox cover screws M8x35 4 22 Nm (16.23 lb ft) -6 Oil breather plug - 1 20 Nm (14.75 lb ft) -7 Oil load cap - 1 25 Nm (18.44 lb ft) -8 Oil drainage plug M10x1 1 20 Nm (14.75 lb ft) -

OPTION 01


CHAR - 15

GEAR SELECTORpos. Description Type Quantity Torque Notes

1 Selector pin (Option 01) - 1 25 Nm (18.44 lb ft) -2 Selector nut (Option 01) - 1 25 Nm (18.44 lb ft) -1 Selector pin (Option 02) - 1 25 Nm (18.44 lb ft) -

OPTION 02


CHAR - 16


1 Main shaft nuts - 2 60 Nm (44.25 lb ft) -


1 Index lever screw M6x12 1 10 Nm (7.38 lb ft) Loctite 2432 Screws M6x16 2 10 Nm (7.38 lb ft) -

OPTION 01


CHAR - 17

ALTERNATOR - REGULATORpos. Description Type Quantity Torque Notes

1 Alternator nut M16 1 90 Nm (66.38 lb ft) Loctite 2432 Front cover fixing screws M5x65 3 6 Nm (4.43 lb ft) -

OPTION 02


CHAR - 18


1 TE Flanged screw M12 - 1.25x50 1 100 Nm (73.76 lb ft) -2 Recessed TCEI screws M6 x 35 3 10 Nm (7.38 lb ft) Loct. 2433 TCEI screw M5 x 12 1 10 Nm (7.38 lb ft) Loct. 243

STARTER MOTORpos. Description Type Quantity Torque Notes

1 Starter motor fixing screws M8x35 2 25 Nm (18.44 lb ft) -


CHAR - 19

THROTTLE BODYpos. Description Type Quantity Torque Notes

1 Pipe fixing screw M6x22 4 10 Nm (7.38 lb ft) -


CHAR - 20

INDEX OF TOPICS

SPECIAL TOOLS S-TOOLS

SPECIAL TOOLSStores code Description19.92.73.00 Bushing for fitting seal ring on secondary

shaft

19.92.72.20 Tool for fitting seal ring on timing systemcover

10.90.72.00 Tool for valve removal and refitting

19.92.61.00 Punch for seal ring of bevel gear set pin-ion

19.92.88.00 Bevel gear set alignment pre-fitting tool

19.92.94.00 Punch for clutch shaft bearing on housing

Special tools Engine V750 IE MIU G3

S-TOOLS - 22

Stores code Description19.92.60.00 Punch for gearcase sealing ring

19.90.59.00 Punch for seal ring on clutch shaft

19.92.72.00 Punch for fitting seal ring on gearbox cov-er (secondary shaft)

19.90.65.00 Tool for clutch plate fitting/centring

19.91.18.00 Flywheel locking tool

19.92.72.02 Spacer for fitting ring on secondary shaft

19.90.70.00 Extractor for internal ring on drilled bolt

Engine V750 IE MIU G3 Special tools

S-TOOLS - 23

Stores code Description19.92.75.00 Extractor for external ring of gearcase

bearing

19.92.62.00 Punch for bearing on bevel gear set pin-ion

19.92.77.00 Transmission gear locking tool for gear-box removal

19.92.63.00 Punch for primary shaft bearing on gear-box

19.92.64.00 Punch for external ring of tapered bearingon bevel gear set pinion holding body

19.92.65.00 Punch for external ring of gearcase bear-ing

19.92.76.00 Extractor for swinging arm holder bearingon gearbox cover


S-TOOLS - 24

Stores code Description020847Y Flywheel extractor

19.92.78.00 Adapter bushing for valve removing tool

19.92.79.00 Punch for pressing bearing inner ring on-to drilled pin

12.91.20.00 Tool to fit the flywheel-side flange togeth-er with seal ring on the crankshaft

19.92.71.00 Tool to fit the seal ring on the flywheel-side flange

020975Y Clutch shaft nut key

19.90.71.60 Clutch shaft locking equipment


S-TOOLS - 25

Stores code Description19.90.25.00 Gearbox support

19.92.60.20 Punch for cap installation on valve guide.

020976Y Punch for fitting the clutch control dustseal

020977Y Punch for refitting the clutch shaft oil seal

020978Y Punch for drive shaft secondary oil gaiterrefitting

19.92.73.20 Tool for fitting seal ring on camshaft tim-ing system cover

19.92.64.60 Inserting tool for outer ring of secondaryshaft bearing


S-TOOLS - 26


S-TOOLS - 27

INDEX OF TOPICS

ENGINE ENG

GearboxCAUTION

THERE CAN BE TWO DIFFERENT TYPES OF GEARBOX ON THE ENGINE WITH 6 GEAR SPEEDS(OPTION 01) OR WITH 5 GEAR SPEEDS (OPTION 02)

OPTION 01



Engine V750 IE MIU G3 Engine

ENG - 29


1 Selector pin (Option 01) - 1 25 Nm (18.44 lb ft) -2 Selector nut (Option 01) - 1 25 Nm (18.44 lb ft) -1 Selector pin (Option 02) - 1 25 Nm (18.44 lb ft) -


1 Crown screws M6x16 6 10 Nm (7.38 lb ft) Loctite 243

Engine Engine V750 IE MIU G3

ENG - 30

pos. Description Type Quantity Torque Notes2 Gearbox screws M8x35 5 25 Nm (18.44 lb ft) -3 Bearing block washers fixing screws TSEI 4 10 Nm (7.38 lb ft) Loct. 2434 Oil load cap - 1 25 Nm (18.44 lb ft) -5 Oil filter cap - 1 .. Nm (... lb ft) -6 Oil pump fixing screw Torx M5x16 1 6 Nm (4.42 lb ft) Loct. 2437 Gearbox fixing screws TCEI M6x55 14 10 Nm (7.38 lb ft) -



OPTION 02


ENG - 31




ENG - 32


1 Main shaft nuts - 2 60 Nm (44.25 lb ft) -


1 Index lever screw M6x12 1 10 Nm (7.38 lb ft) Loctite 2432 Screws M6x16 2 10 Nm (7.38 lb ft) -

Diagram

OPTION 01


ENG - 33

key:

1. Thrust washer

2. 2nd speed gear on main shaft

3. Circlip

4. Thrust washer

5. 6th speed gear on main shaft

6. Floating bushing

7. Main shaft thrust washer

8. 3rd and 4th speed sliding gear on main shaft

9. Circlip for the shaft

10.Thrust washer

11.5th speed gear on main shaft

12.Floating bushing

13.Main shaft with PI

14.Thrust washer

15.Transmission shaft

16.2nd speed gear on transmission shaft

17.Floating bushing

18.Thrust washer

19.Circlip for the shaft

20.6th speed gear on transmission shaft



ENG - 34

22.Thrust washer

23.3rd speed gear on transmission shaft

24.Floating bushing


26.Floating bushing

27.Thrust washer




31.Thrust washer

32.1st speed gear on transmission shaft

33.Floating bushing

34.Thrust washer

OPTION 02

key:

1. Safety nut

2. Bearing AP 17x40x17.5

3. 2nd gear AP Z=14

4. 3rd gear AP Z=18

5. Shim washer

6. 4th gear AP Z=18


ENG - 35

7. Seeger ring

8. Shim washer

9. 5th gear AP Z=25

10.Roller cage

11.Main shaft Z=11

12.Bearing AP 20x37x17

13.Transmission gear AP Z=21

14.Thrust washer

15.Safety nut

16.Seeger ring

17.Spacer

18.Sealing ring 18.77x1.78

19.Bearing 20x47x14

20.Spacer

21.Drip unit

22.Transmission shaft

23.2nd gear AS Z=23

24.Thrust washer

25.3rd gear AS Z=23

26.Shim washer

27.4th gear AS Z=19

28.Shim washer

29.Seeger ring

30.5th gear As Z=22

31.1st gear AS Z=26

32.Thickness

33.Bearing

34.Seeger ring

Gearbox

OPTION 01


ENG - 36



OPTION 02


ENG - 37



Removing the gearbox

• Remove the gearbox fixing screws

from the engine.

• Remove the gearbox.

Gearbox shafts

Disassembling the gearbox

OPTION 01


ENG - 38

• Remove the 14 fixing screws of the

gearbox

• Remove the pusher plate

• Remove the neutral sensor and take

the gasket washer

• Remove the intermediary body (1), the thrust bearing (2) and the external body (3)


ENG - 39

• Remove the gearbox cover with a few

mallet strokes

• To remove the bearings fitted in the

gearbox crankcases, the safety wash-

er must be removed firstCAUTIONPAY ATTENTION WHEN REMOVING THE BEARING SAFE-TY WASHERS, THEY HAVE TWO DIFFERENT SIZES.THE SMALL WASHERS MAY BE PLACED ERRONEOUSLYINSTEAD OF THE ONES WITH LARGER SIZE

• The bearings from the gearbox crank-

cases can be removed using generic

extractors.

• Remove the drive shaft secondary oil

gaiterCAUTIONIN CASE OF OIL SEAL REPLACEMENT, USE THE SUITA-BLE PUNCH UNTIL IT REACHES THE CRANKCASE

Specific tooling020978Y Punch for drive shaft secondary oilgaiter refitting

OPTION 02


ENG - 40

• Remove the gearbox

• Fit the clutch shaft onto the gearbox so

that the gear becomes engaged with

the primary shaft gear.

• Install the specified locking tool onto

the clutch shaft splines.

• Unscrew the transmission gear retain-

ing nut and slide off the thrust washer.


ENG - 41

• Remove the gear and the clutch shaft.

• Unscrew the breather cap with its pawl.

• Unscrew and remove the neutral indi-

cator.


ENG - 42

• Unscrew the gearbox cover bolts and

remove the cover tapping it with a mal-

let.

• Slacken the lock nut and unscrew the

pre-selector positioning eccentric

screw.


ENG - 43

• Slide off the pre-selector and remove

the pre-selector seal ring.

• After unscrewing the retaining plate fixing screws, remove the complete set of gears, shafts

and forks.

See alsoRemoving the gearbox

Removing the primary shaftCAUTION

REPLACE THE SEEGER RINGS DURING REFITTING

OPTION 01


ENG - 44

• Remove the gear selector shaft, the

desmodromic shaft and the forks with

shaft

• Remove the complete gear unit

To dismantle the main shaft, proceed as follows:

• Remove the shim washer (1)

• Remove the gear of the 2nd gear (2)

• Remove the seeger ring (3)


ENG - 45

• Remove the spacer (4)

• Remove the gear of the 6th gear (5)

• Remove the bushing (6)



ENG - 46

• Remove the gear of the 3-4th gear (8)





ENG - 47


• Remove the washer (13) from the main

shaft (14)

OPTION 02

• Remove the fastening nut (1) of the

bearing on the main shaft

• Remove the bearing (2) using a gener-

ic bearing extractor


ENG - 48

• Remove the retaining plate (3)


• Remove the gear of the 3rd gear (5)

• Remove the shimming washer (6)


ENG - 49






ENG - 50

• Remove the roller semi-cases (11)

Removing the secondary shaftCAUTION

REPLACE THE SEEGER RINGS DURING REFITTING

OPTION 01

To dismantle the transmission shaft, proceed as

follows:


• Remove the gear of the first gear (2)



ENG - 51






ENG - 52






ENG - 53






ENG - 54





OPTION 02


ENG - 55


• Remove the bearing (2)

• Remove the washer (3)

• Remove the gear of the 1st gear (4)


ENG - 56






ENG - 57


• Remove the rubber sealing ring (10)

• Remove the bearing (11)

• Remove the retaining plate (12)


ENG - 58



• Remove the thrust washer (15)


Desmodromic demounting

OPTION 01


ENG - 59

• Remove the gearbox selector

• Remove the sliding shaft of the forks

(1)

• Remove the desmodromic shaft (2)

• The forks are marked with a serial

number that indicated the correct posi-

tioning.

• Remove the upper fork No.1 (3)

• Remove the central fork No.2 (4)


ENG - 60

• Remove the lower fork No.3 (5)

OPTION 02

• Remove the fixing screw (1) of the in-

dex lever (2)

• Remove the gear selector (3)

• Remove the fixing screws (4) of the re-

taining plate

• Remove the complete gear unit from

the gearbox and remove the retaining

plate (5)


ENG - 61

• Release the main shaft (6) and the

transmission shaft (7) from the forks

• Remove the upper fork (6) from the

desmodromic shaft by sliding the guide

towards the grooves of the guide itself

• Remove the central fork (7) from the

desmodromic shaft by turning and slid-

ing the guide towards the grooves of

the guide itself

• Remove the lower fork (8) from the

desmodromic shaft by turning and slid-

ing the guide towards the grooves of

the guide itself

Disassembling the clutch shaft

OPTION 01


ENG - 62

• Using the appropriate specific tools, re-

move the clutch shaft fastening nut

Specific tooling020975Y Clutch shaft nut key

19.90.71.60 Clutch shaft locking equipment

• Remove the clutch shaft with a few

mallet (1) strokes

• Remove the oil seal from the clutch

shaftCAUTIONIN CASE OF OIL SEAL REPLACEMENT, USE THE SUITA-BLE PUNCH UNTIL IT REACHES THE CRANKCASE

Specific tooling020976Y Punch for fitting the clutch controldust seal

• Remove the spacer (2)CAUTION

DURING REFITTING, PAY ATTENTION TO THE DIRECTIONOF THE SPACER, THE CONICAL PART MUST BE ORIEN-TED INWARD SO AS TO AVOID O-RING DAMAGES


ENG - 63

• Remove the O-ring (3)

• Remove the oil sealCAUTIONIN CASE OF OIL SEAL REPLACEMENT, USE THE SUITA-BLE PUNCH UNTIL IT REACHES THE CRANKCASE

Specific tooling020977Y Punch for refitting the clutch shaft oilseal

OPTION 02

• Remove the clutch bell.

• Undo the three screws with washers

and remove the bearing retaining

plate.


ENG - 64

• Undo the clutch shaft fixing nut.

• Slide off the clutch shaft and remove

the seal ring.

See also

Clutch bell removal

Controllo alberi

Check transmission gears for signs of pitting and wear and replace damaged gears if necessary.

Check the gear fitting teeth for cracks, damage and wear and replace those damaged if necessary.

Check the transmission gears movement and, if it is not regular, replace the damaged part.

Checking the desmodromic drum

Check the desmodromic drum for damage, scratches and wear and replace the assembly if required.


ENG - 65

Checking the forks

Check that the forks work area are well levelled and are not worn, so as to have lost the toughening

characteristics and that the nose-pieces operating in the drum splines are not excessively worn, oth-

erwise replace the forks.

Assembling the clutch shaft

• Fit the clutch shaft using a plastic mal-

let and refit circlip and seal ring.


ENG - 66

• Position the retaining plate and tighten

the screws with their washers with

threadlocker.

Gear selector

Removing the gear selector

OPTION 01


ENG - 67

• Remove the complete gearbox selec-

tor shaft from the crankcase (1)

• Remove the spring from the index lever

(2)


• Remove the ring (9)


ENG - 68




• Remove the selector spring (8)


ENG - 69

• Remove the ring (9)

• Remove the bushing (10)WARNINGDURING REFITTING, PAY ATTENTION TO THE CORRECTPOSITIONING OF THE BUSHING, AS THE SIDES ARE NOTSYMMETRICAL

• Remove the index lever (11)

• Remove the bushing (12)WARNINGDURING REFITTING, PAY ATTENTION TO THE CORRECTPOSITIONING OF THE BUSHING, THE SIDES ARE NOTSYMMETRICAL


ENG - 70

• Remove the selector return spring (13)

OPTION 02

• Remove the complete pre-selector (1)

sliding it off from the crankcase

• Remove the spring (2) and the spacer

• Remove the counter nut and the fixing

nut of the eccentric screw


ENG - 71

• Remove the eccentric screw

• Remove the selector spacer

Flywheel


1 Oil plug - 1 15 Nm (11.06 lbf ft) Loctite 6012 Connecting rod screws - 4 33 Nm (24.34 lbf ft) -


ENG - 72

pos. Description Type Quantity Torque Notes3 Flywheel screws - 6 42 Nm (30.98 lbf ft) Loctite 243

Removing the flywheel

• Remove the gearbox.

• Remove the retainer ring and the

clutch engagement/disengagement

cap.

• Unscrew the screws securing the pres-

sure plate flywheel to the crankshaft

and then remove it.


ENG - 73

Checking

• Check that the flywheel surface that

contacts the plate is not scratched.

• Check that the contact faces on the

crankshaft are not distorted; if they are,

replace the flywheel.

Installing the flywheel

• When refitting the pressure plate fly-

wheel onto the crankshaft, make sure

the "yellow mark" on the shaft is per-

fectly aligned with the slot on the en-

gine flywheel.

• Tighten the screws and fit the specified

flywheel locking tool.

Specific tooling19.91.18.00 Flywheel locking tool

• Tighten the screws following a criss-

cross pattern with a torque wrench set

to the prescribed torque. It is advisable

to change the fixing screws securing

flywheel to crankshaft.


ENG - 74

• Insert the clutch engagement/disen-

gagement cap with its retainer ring.

Generator

OPTION 01


1 TCEI screw M6x25 10 10 Nm (7.37 lb ft) -


ENG - 75

pos. Description Type Quantity Torque Notes2 TCEI screw M6x30 2 10 Nm (7.37 lb ft) -3 Alternator cover screws M6x35 5 10 Nm (7.37 lb ft) Loctite 243

OPTION 02


1 TCEI screw M6.15x11 10 10 Nm (7.37 lb ft) Loct. 2432 TCEI screw M6.15x0.8 1 10 Nm (7.37 lb ft) Loct. 243

OPTION 01


ENG - 76


1 Alternator nut M16 1 90 Nm (66.38 lb ft) Loctite 2432 Front cover fixing screws M5x65 3 6 Nm (4.43 lb ft) -

OPTION 02


ENG - 77


1 TE Flanged screw M12 - 1.25x50 1 100 Nm (73.76 lb ft) -2 Recessed TCEI screws M6 x 35 3 10 Nm (7.38 lb ft) Loct. 2433 TCEI screw M5 x 12 1 10 Nm (7.38 lb ft) Loct. 243

Revolution sensor

• Undo and remove the two screws and

remove the sensor.

• Position the engine speed sensor on

the timing system cover and tighten the

two fastening screws to the prescribed

torque.

Generator removalCAUTIONNOTETHERE ARE TWO DIFFERENT TYPES OF FLYWHEEL/ALTERNATOR IN THIS ENGINE. THECOMPONENTS CANNOT BE INTERCHANGED AS WELL AS THE TOOLS USED FOR THEIRLOCKING AND REMOVAL.BELOW ARE SHOWN THE PROCEDURES FOR THE REMOVAL AND INSTALLATION OF THEFLYWHEELS/ ALTERNATORS.OPTION 01


ENG - 78

• Unscrew the fixing screws and remove

the alternator unit protection covers

• Unscrew the screws fixing the stator to

the timing system cover and slide off

the stator.


ENG - 79

• Unscrew the nut fixing the rotor to the

crankshaft, slide off the rotor, remove

the key and collect the washer.

OPTION 02

• Remove the alternator cover fixing

screws

• Remove the alternator cover


ENG - 80

• Remove the rotor fixing screw

• Insert in the rotor hole the specific

spacer

• Place and tighten the tool (1) on the ro-

tor.


ENG - 81

• Tighten the threaded pin (2) of the tool

and proceed with the rotor removal.

• Operating on the alternator cover, pro-

ceed with the removal of the stator wir-

ing lock plate

• Removing the three stator fixing

screws makes it possible to disconnect

it

Generator Installation

OPTION 01

• Insert supporting washer, key and ro-

tor, and tighten the nut to the prescri-

bed torque with a torque wrench.


ENG - 82

• Fit stator and cover and tighten the

three screws.

• Fit stator cover.


ENG - 83

• Tighten the five cover fixing screws to

the prescribed torque.

OPTION 02

• Place the stator and its wiring on the

cover

PAY ATTENTION TO APPLY ON THE RUBBER

COMING OUT OF THE COVER THE ThreeBond

SEALANT.

• Place the wiring locking plate and fix it

with the specific screw.

• Fix the stator with the three screws.

• Place the rotor and fix it with the screw


ENG - 84

• Place the timing system cover and pay

attention to place the gasket

• Place the 12 cover fixing screws and

tighten them to the prescribed torque

Starter motor

STARTER MOTORpos. Description Type Quantity Torque Notes

1 Starter motor fixing screws M8x35 2 25 Nm (18.44 lb ft) -


ENG - 85

Removing the starter motor

• Remove the starter motor fixing

screws.

• Slide off the starter motor.

Clutch side


ENG - 86




1 Crown screws M6x16 6 10 Nm (7.38 lb ft) Loctite 2432 Gearbox screws M8x35 5 25 Nm (18.44 lb ft) -3 Clutch belt cover screws M6x30 11 10 Nm (7.38 lb ft) Loctite 243

Clutch bell removal

• Secure gearbox/clutch bell to the sup-

port clamped in a vice, fit the nut lock-

ing tool and turn the shaft using the

suitable tool to loosen the nut.


ENG - 87

• Loosen the Allen screws that secure

the clutch bell to the gearbox.

• Detach and remove the clutch bell to-

gether with the clutch shaft tapping

lightly around clutch bell edge.


ENG - 88

• Remove the gasket.

Disassembling the clutch

• Remove the clutch cover.

• Fit the specified flywheel locking tool

on the crankcase.


• Unscrew the clutch plate fixing screws

and remove clutch plate together with

starting sprocket.

See also

Clutch bell removal


ENG - 89

• Remove the clutch plate.

Checking the clutch plates

Clutch plates

Make sure that the clutch plate is not scratched or badly worn.

Check the flexible coupling springs and make sure

that clutch plate thickness is not lower than the

specified value: if so, replace the clutch plate.

Starting sprocket

Check that the supporting surface with the driven

plate is perfectly smooth and even.

Also check that the toothing where the starter mo-

tor pinion works is not chipped or scratched; oth-

erwise, replace it.


ENG - 90

Assembling the clutch

• Install the flywheel locking tool.


• Insert the cap with its seal ring.

• Position the specified clutch plate cen-

tring tool on the plate and fit the plate

into place.

Specific tooling19.90.65.00 Tool for clutch plate fitting/cen-tring


ENG - 91

• Fit the assembly on the pressure plate

flywheel and tighten the screws to the

prescribed torque.

Clutch bell fitting

• Fit the clutch shaft.

• Position the clutch bell gasket and fit

the clutch bell into place.

See alsoAssembling theclutch shaft


ENG - 92

• Snug the Allen nuts and the external

screws and tighten them to the prescri-

bed torque.

• Tighten the clutch shaft nut using the

suitable tool and squash.

Specific tooling19.90.71.60 Clutch shaft locking equipment

• Insert the breather cap.


ENG - 93

• Tighten the neutral switch.

• Insert the clutch control rod into the

shaft with the larger diameter facing

the control lever.

Head and timing


1 Central stud bolt M8x143 2 20 Nm (14.75 lb ft) Loctite 5422 Short stud bolt M10x182 4 42 Nm (30.98 lb ft) -


ENG - 94

pos. Description Type Quantity Torque Notes3 Long stud bolt M10x214 4 42 Nm (30.98 lb ft) -4 Nuts - pre-tightening M10x1.5 4 25 Nm (18.44 lb ft) -4 Nuts - tightening M10x1.5 4 42 Nm (30.98 lb ft) -5 Column nut - 4 25 Nm (18.44 lb ft) -6 Nut - 2 28 Nm (20.65 lb ft) -7 Internal Head cover screws M6x25 4 8-10 Nm (5.90-7.37 lb

ft)-


-



Removing the head cover

• Remove the spark plug cover

• Disconnect the spark plug tube

• Remove the blow-by pipe

• Undo the head cover fixing screws


ENG - 95

• Loosen the central fastening screws

• Remove the head cover

• Remove the gasket

• Check that the mating faces that contact the heads are not damaged or blistered.

Removing the cylinder head

• The following instructions refer to one

head, but apply to both.

• Remove the head cover.

• Unscrew the spark plug


ENG - 96

• Loosen the fastening nuts of the rocker

cam tower.

See alsoRemoving thehead cover

• Remove the rocker cam tower and col-

lect the plates

• Remove the rocker rods

• Remove the outer nuts that fix the head

to the cylinder and collect the washer


ENG - 97

• Remove the internal screws fixing the

head to the cylinder

• Remove the complete head from the

cylinder

• Remove the cylinder head gasket

Cylinder head

Removing the rocker armsNOTE

THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTHHEADS.

• Remove the head cover.


ENG - 98

• Remove the circlips, slide off the two

rockers and the oil delivery fitting.

See alsoRemoving thehead cover


ENG - 99

Removing the valves

• Place the special tool on the upper cap

of the valve to be removed and at the

centre of the head of the valve.

Specific tooling10.90.72.00 Tool for valve removal and refitting

19.92.78.00 Adapter bushing for valve remov-ing tool

Close the tool to compress the spring, and then hit

the tool head with a mallet so that the two cotters

get detached from the upper cap.

• Unscrew the tool and remove it from

the head.

• Slide off the upper cap, the spring and

finally the valve.


ENG - 100

• Remove the valve guide seals and ex-

tract the lower cap of the springs.

VALVE GUIDES MUST BE REPLACED WHEN THEY AREWORN TO THE POINT THAT REPLACING THE VALVEALONE IS NOT ENOUGH TO ELIMINATE CLEARANCE BE-TWEEN VALVE STEM AND VALVE GUIDE BORE.


ENG - 101

• Valve guides need to be knocked out

tapping from the inside with punch and

mallet; heat the head up to approxi-

mately 50-60 °C to aid removal.

Specific tooling19.92.60.20 Punch for cap installation on valveguide.

Checking the rocker arms

• Check that the bolt surface that con-

tacts the rockers is not exceedingly

worn.

• Check the rocker to valve and rocker to

rod contact surfaces.

Inspecting the springs and half-cones

With the assembly installed (retainers, springs, valves and cotters in the heads), the compressed ex-

ternal springs should measure 36 mm (1.4173 in). Please note that the valves should have a remaining

lift of 1 mm (0.039 in) when fully open before the internal spring becomes fully compressed. If not so,

remove or add shims until achieving this condition.


ENG - 102

Unloaded length

SPRING SPECIFICATIONSSpecification Desc./Quantity

Inside diameter 17.8 ± 0.2 mm (0.7007 ± 0.0079 in)Wire diameter 3.4 ± 0.03 mm (0.1338 ± 0.0012 in)

Unloaded length 43.6 mm (1.7165 in)Compressed length 27.5 mm (1.0827 in)

Test length L1 36 mm (1.4173 in)Test length L2 28 mm (1.1024 in)


ENG - 103

Specification Desc./QuantityDetected test load P1 17.6 ± 5% Kg (38.8013 ± 5% lb)Detected test load P2 44 ± 3% Kg (97.0033 ± 3% lb)

Hand rightSpring class according to UNI 7900/4 CC

Checking the cylinder headCAUTION

VALVE SEAT GRINDING AFTER VALVE GUIDE REPLACEMENT OR WHEN THE VALVES LEAK.• Once you have chosen the pilot tool,

insert it into the valve guide seat and

lock it in place.

• Choose the proper cutter to suit valve

seat diameter and angle.

• Insert the cutter into the pilot tool and

push it down gently until it contacts the

valve seat.


ENG - 104

• Insert the T handle into the cutter and

turn clockwise while pressing lightly

achieving an even valve contact sur-

face.

• Repeat the procedure using the suita-

ble cutter to achieve the correct valve

seat sealing surface.


ENG - 105

• Remove any tools you have used to

complete the procedure.

• Insert the lower spring seats and fit the

seal rings onto the valve guide using

the specified tool.

Installing the valves

• Press the valve guides into the heads

from the outside towards the inside us-

ing punch and mallet; it is advisable to

heat the head to approximately 60 °C

(140 °F) before proceeding.

Specific tooling19.92.60.20 Punch for cap installation on valveguide.

• Insert the valve guides into their seats

and bore them out to the size indicated

in the table with a reamer.

VALVE AND GUIDE COUPLING DATAVALVE GUIDE INSIDE Ø mm (in) VALVE STEM Ø mm (in) FITTING CLEARANCE mm

(in)Intake 5.500-5.520 (0.2165-0.2173) 5.480-5.465 (0.2157-0.2151) 0.020-0.055Exhaust 5.500-5.520 (0.2165-0.2173) 5.480-5.465 (0.2157-0.2151) 0.020-0.055


ENG - 106

INTAKEA Ø mm (in) B (nominal) Ø mm (in) C (nominal) Ø mm (in) D mm (in)

32.0-32.25 (1.2598-1.2697) 34 (1.3386) 1.42 (0.0559) 1 (0.0394)

EXHAUSTA Ø mm (in) B (nominal) Ø mm (in) C (nominal) Ø mm (in) D mm (in)

27.72-27.97 (1.0913-1.1012) 30 (1.1811) 1.6 (0.0630) 1.14 (0.0448)


ENG - 107

Installing the rocker arms

• Make sure that the longitudinal slot is

pointing to the oil delivery passage.WHEN REFITTING, PAY SPECIAL ATTENTION TO THEMOUNTING POSITION OF THE WASHERS.

• Insert the oil delivery fitting and the

rockers on the shaft and lock them in

place with the circlips.


ENG - 108

• Check that the rocker rods are straight

and that the contact surfaces at the

ends show no signs of seizing; other-

wise, replace it.

• To check the pressed ends on the rods

(pads) for looseness, simply drop the

rods from a small height on a flat sur-

face; on impact, you should hear a

sharp clank: this means the pads have

no clearance.

Adjusting valve clearance

• Bring the piston of the left cylinder to

top dead centre making sure that the

reference mark on the crankshaft gear

is up on the perpendicular axis.

• Place the camshaft with the reference

pin of the gear pointing downwards.


ENG - 109

• Use a feeler gauge to check that the

clearance between the valve and the

set screw corresponds with the indica-

ted values. When the valve clearance

values, intake and exhaust respective-

ly, are different from the ones indicated

below, adjust them by loosening the

lock nut and operate on the set screw

with a screwdriver.

• Intake: 0.15 mm (0.0059 in) (when

cold)

• Outlet: 0.20 mm (0.0079 in) (when

cold)


ENG - 110

Timing


1 TCEI screw M6x25 10 10 Nm (7.37 lb ft) -2 TCEI screw M6x30 2 10 Nm (7.37 lb ft) -3 Alternator cover screws M6x35 5 10 Nm (7.37 lb ft) Loctite 243


ENG - 111



TIMING SYSTEM COVER REMOVAL

• Remove alternator and cover to get ac-

cess to the timing system.

• Undo the fixing screws and remove the

timing system cover with its gasket.

REFITTING THE TIMING SYSTEM COVER

• Insert the gasket, position the timing system cover and tighten to the prescribed torque using

a torque wrench.


ENG - 112

Removing the chain tensioner

• Remove the timing system cover.

• Remove the chain tensioner.

• Collect the washer.

See alsoTiming

Chain removal

• Remove the tone wheel.

• Remove the two screws, slide the tim-

ing gear off the shaft, remove chain

and oil pump gear.

• Collect the washer.


ENG - 113

See alsoRemoving the phonic wheel

Removing the phonic wheel

• Remove the engine unit from the chas-

sis.

• Remove the timing system cover.

• Remove the chain tensioner.

• Unscrew and remove the tone wheel

fixing screw and collect the washer.

See alsoRemoving thechain tensionerTiming


ENG - 114

Installing the phonic wheel

• Tone wheel position is dictated by the

pin on the camshaft.

• Position the tone wheel making sure it

locates correctly on the camshaft (see

slot) and tighten to the prescribed tor-

que using a torque wrench.

Cam timing

• Bring the piston of the left cylinder to

top dead centre making sure that the

reference mark on the crankshaft gear

is up on the perpendicular axis.


ENG - 115

• Place the camshaft with the reference

pin of the gear pointing downwards.

• Insert the oil pump shaft (pin) key.

• Fit the two gears with the timing chain;

after installation, check the position of

the reference notches and tighten the

screws to the prescribed torque with a

torque wrench.


ENG - 116

• Tighten the oil pump nut while holding

the oil pump shaft steady.

• Fit the chain tensioner and tighten to

the prescribed torque using a torque

wrench.


ENG - 117

Cylinder-piston assembly


1 Central stud bolt M8x143 2 20 Nm (14.75 lb ft) Loctite 5422 Short stud bolt M10x182 4 42 Nm (30.98 lb ft) -3 Long stud bolt M10x214 4 42 Nm (30.98 lb ft) -4 Nuts - pre-tightening M10x1.5 4 25 Nm (18.44 lb ft) -4 Nuts - tightening M10x1.5 4 42 Nm (30.98 lb ft) -5 Column nut - 4 25 Nm (18.44 lb ft) -6 Nut - 2 28 Nm (20.65 lb ft) -7 Internal Head cover screws M6x25 4 8-10 Nm (5.90-7.37 lb

ft)-


-


ENG - 118

Removing the cylinder

• Remove the head.

• Slide off the cylinder from the stud

bolts.

• Remove the gasket from the stud bolts

See alsoRemoving thecylinder head

• Remove the O-ring of the lubrication

duct of the thermal unitCAUTIONPAY PARTICULAR ATTENTION TO ENSURE THAT THE O-RING DOES NOT FALL INSIDE THE CRANKCASE


ENG - 119

Disassembling the piston

• After protecting the cylinder seat, re-

move the two snap rings that retain the

piston pin

• Slide off the pin using the specified tool (turn the tool screw) and remove the piston.CAUTION

DURING SERVICING, CLEAN OFF ANY DEPOSITS FROM PISTON CROWN AND CIRCLIPGROOVES

Checking the cylinder

• After checking for scoring, check cylin-

der surface wear using a dial gauge

graduated in hundredths of a millime-

tre.

• Measure the inner diameter of the cyl-

inders at three different heights, turn

the dial gauge (graduated in hun-

dredths of a millimetre) 90° and repeat

the measurements; set the dial gauge

graduated in hundredths of a millimetre

to zero using a ring gauge before

measuring.

Key:

1. 1st measurement


ENG - 120

2. 2nd measurement

3. 3rd measurement

4. measurement for classification

Checking the piston

• After checking for scoring, check cylin-

der surface wear using a dial gauge

graduated in hundredths of a millime-

tre.

• Measure the inner diameter of the cyl-

inders at three different heights, turn

the dial gauge (graduated in hun-

dredths of a millimetre) 90° and repeat

the measurements; set the dial gauge

graduated in hundredths of a millimetre

to zero using a ring gauge before

measuring.

Key:

1. 1st measurement

2. 2nd measurement

3. 3rd measurement

4. measurement for classification


ENG - 121

Inspecting the piston rings

PISTON RINGS AND OIL SCRAPER REMOVAL

• Remove piston rings and oil scraper.CAUTIONPUSH THE PISTON RING END GAPS APART JUSTENOUGH TO EASE THE PISTON RINGS OFF THE PISTONTO AVOID BREAKING THEM

• Insert the piston rings into the cylinder

and check clearance at end gaps using

a feeler gauge.

Top piston ring: mm 0.20 - 0.35 (in 0.0079 -

0.0138);

Intermediate piston ring: mm 0.35 - 0.55 (in 0.0138

- 0.0216);

oil scraper ring: mm 0.20 - 0.70 (in 0.0079 -

0.0275).

PISTON RINGS AND OIL SCRAPER REFITTING

• Insert the piston rings paying attention

to their mounting direction and end gap

arrangement; the end gaps must be

approximately 120 degrees from each

other.


ENG - 122

Fitting the piston

• To refit the piston into the connecting

rod small end, heat up the piston in an

oil bath up to approximately 60°C (140°

F); this will cause the piston to expand

slightly and facilitate pin insertion.

• Insert the retaining clip into the piston

and fit the specified pin insertion tool to

the piston.

• Position the piston with the tool attach-

ed on the connecting rod in order to

install the pin.

• When finished, remove the tool and in-

sert the second snap ring that closes

the piston pin seat, after protecting the

cylinder seat.CAUTIONMOUNTING POSITION IS INDICATED BY AN ARROWPOINTING IN THE DIRECTION OF TRAVEL


ENG - 123

Installing the cylinder

• Check that the piston ring end gaps are approximately 120 degrees from each other.

• Position the O-ring on the lubrication

duct of the thermal unit

• Fit a new gasket

• Place a commercially available appro-

priate ring clamp on the piston.


ENG - 124

• As soon as past the piston ring area,

remove the piston ring compressor

clamp from the piston and insert the

cylinder into its seat.

• Install the head.

See alsoInstalling thecylinder head

Selecting the cylinder

CYLINDER SELECTION ØGRADE "D" mm (in) GRADE "E" mm (in) GRADE "F" mm (in)

80.000 - 80.010 (3.1496 - 3.1500) 80.010 - 80.020 (3.1500 - 3.1504) 80.020 - 80.030 (3.1504 - 3.1508)

When fitting new units, grade "D-E-F" cylinders must be matched with corresponding grade "D-E-F"

pistons.

Fitting clearances between piston and cylinders: 0.050 - 0.070 mm (0.0020 - 0.0027 in).

Selecting the piston

• Check the diameter of the piston at the

specified height, perpendicular to the

pin axis.

• Selection values refer to the bare pis-

ton (without graphite coating).


ENG - 125

• Check that the piston bears the selec-

tion mark and the arrow that denotes

mounting position.

PISTON Ø SELECTIONGRADE "D" mm (in) GRADE "E" mm (in) GRADE "F" mm (in)

79.940 - 79.950 (3.1472 - 3.1476) 79.950 - 79.960 (3.1476 - 3.1480) 79.960 - 79.970 (3.1480 - 3.1484)CAUTION

THICKNESS OF THE NEW PAINTED ANTI-FRICTION COATING: 0,015 ± 0,020 mm (0.00059 ±0.00079 in)

PIN AND PISTON EYE COUPLING DATAPIN OUTER Ø mm (in) PISTON EYE ø mm (in) FITTING CLEARANCE and

INTERFERENCE FIT mm (in)21.994 - 21.998 (0.8659 - 0.8661) 22.000 - 22.006 (0.8661 - 0.8664) From 0.006 mm (0.00024 in) clearance

to 0.002 mm (0.0008 in) interference fit

Installing the cylinder head

• Insert the new gasket and fit the cylin-

der head into place.


ENG - 126

• Fit the rocker lower spacers, the rocker

control rods, the rockers and the upper

spacers with their nuts.


ENG - 127

• Tighten the nuts to the prescribed tor-

que following a crisscross pattern.

Installing the head cover

• Replace the head cover gaskets and

refit the covers to the heads.


ENG - 128

• Tighten the screws following a criss-

cross pattern with a torque wrench set

to the prescribed torque.


ENG - 129

Crankcase - crankshaft


1 Column nuts - 4 42 Nm (30.98 lbf ft) -2 Nut M8x1.25 6 22 Nm (16.22 lbf ft) -3 TCEI screw M6x25 12 10 Nm (7.37 lbf ft) -4 Oil drainage plug M10x1 1 40 Nm (29.5 lbf ft) -- Spark plugs - 2 30 Nm (22.13 lbf ft) -


ENG - 130


1 Oil plug - 1 15 Nm (11.06 lbf ft) Loctite 6012 Connecting rod screws - 4 33 Nm (24.34 lbf ft) -3 Flywheel screws - 6 42 Nm (30.98 lbf ft) Loctite 243

Splitting the crankcase halves

• Unscrew the four long nuts from inside

the crankcase and the six external

nuts.

• Insert a rod into the seat of the linkage

joining engine and chassis, then tap

the rod lightly with a plastic mallet until

separating the two crankcase halves.


ENG - 131

• Remove the upper crankcase being

careful not to damage its mating face.

• Remove the crankshaft together with

connecting rods and half-bearings.

Unscrew the oil pressure sensor from the upper

crankcase and remove the retaining bushing of the

camshaft; remove the shaft and the tappets, noting

their positions.


ENG - 132

Removing the crankshaft

• Remove the crankshaft connecting

rods.

• Unscrew the oil plug and thoroughly

clean the oilway and oil passages de-

livering oil to connecting rods and main

journals.


ENG - 133

See alsoDisassembling the connecting rod

Disassembling the connecting rod

After removing the crankshaft together with the

connecting rods from the upper crankcase, loosen

the screws and separate connecting rod from

small end noting the reference marks and mount-

ing direction.

• Remove the half-bearings from con-

necting rods and small ends.CAUTIONREPEAT THE PROCEDURE FOR THE OTHER CONNECT-ING ROD


ENG - 134

Inspecting the crankcase halves

• Check that the mating faces are not

damaged, dented or scored. Remove

any liquid gasket residues with thry-

chlorethylene.

• Check that the threads of the stud bolts

are not dented or stripped; if they are,

replace the stud bolt or stud bolts.

• Blow all oil galleries of the two crank-

case halves with compressed air.


ENG - 135

Inspecting the crankshaft components

• Smear the thread of the cap with threa-

dlocker and tighten the cap firmly.

• Blow with compressed air to clean the

lubrication passage seats.CAUTIONTHE CRANKSHAFT IS NITRIDED AND CANNOT BEGROUND; IF WORN, TAPERED OR DEEPLY SCORED, THECRANKSHAFT MUST BE REPLACED

CRANKSHAFT CHECKSpecification Desc./Quantity

Main journal diameter on timing system side 40.02 - 40.004 mm (1.5756 - 1.5750 in)Timing system side main bearing seat diameter 43.67 - 43.657 mm (1.7193 - 1.7188 in)

Total thickness for timing system side main bearings 1.807 - 1.817 mm (0.0711 - 0.0715 in)Clearance between shaft and timing system side bearing 0.007 - 0.048 mm (0.0002 - 0.0019 in)

Clutch side main journal diameter 43.023 - 40.007 mm (1.5757 - 1.6932 in)Clutch side main bearing seat diameter 47.142 - 47.13 mm (1.8560 - 1.8555 in)

Total thickness for clutch side main bearings 2.042 - 2.052 mm (0.0804 - 0.0808 in)Clearance between shaft and clutch side bearing 0.007 - 0.047 mm (0.0002 - 0.0018 in)

Crankshaft shoulder quota 24.77 - 24.803 mm (0.9752 - 0.9765 in)Crankcase shoulder quota 24 - 19.95 mm (0.9449 - 0.7854 in)

Thickness of thrust half ring on clutch side main bearing 2.31 - 2.36 mm (0.0909 - 0.0929 in)Thrust clearance of crankshaft in crankcase 0.05 - 0.233 mm (0.0020 - 0.0092 in)

Crank pin diameter 39.995 - 40.011 mm (1.5746 - 1.5752 in)


ENG - 136

The maximum parallelism deviation of the two crankshaft axes (connecting rod pin and main journals

on flywheel side and timing system side) should not exceed 0.02 mm (0.0009 in) at 40 mm (1.5748 in)

distance.

Checking the connecting rod

• Measure connecting rod pin diameter across the pin and again at 90° degrees away. Meas-

ure bearing seats on both timing system and flywheel side at the half-bearing locations.

• Assemble the connecting rod without half-bearings and tighten the connecting rod screws

to the prescribed torque. Measure the outer diameter of half-bearing locations with a dial

gauge graduated in hundredths of a millimetre and the thickness of both half-bearings with

a round tip micrometer.

• Check the bushings pressed in the small end of the connecting rod for notches due to seizing

or deep scoring; replace as required.

Seat diameter 43.657-43.670 mm (1.7188 - 1.7193 in).

Shaft diameter 39.995-40.001 mm (1.5746 - 1.5748 in).

Clearance between shaft and connecting rod bearing at 90° away from mating faces: min 0.020 (0.0008

in), max 0.061 (0.0024 in).

CONNECTING ROD BEARING THICKNESSESSTANDARD (stock production) A mm (in) STANDARD (stock production) B mm (in)

1.537-1.543 (0.0605 - 0.0607) 1.527-1.533 (0.0601 - 0.0603)


ENG - 137

DIAMETER OF PRESSED SMALL END BUSHING AND PISTON PININNER ø FOR PRESSED SMALL END

BUSHING mm (in)PISTON PIN ø MOUNTING CLEARANCE BETWEEN

SMALL END BUSHING AND PISTONPIN mm (in)

18.010-18.020 (0.7090 - 0.7094) 21.994-21.998 (0.8659 - 0.8661) 0.005-0.021 (0.0002 - 0.0008)

CONNECTING ROD CHECKSpecification Desc./Quantity

Diameter of the connecting rod head 43.657 - 43.67 mm (1.7188 - 1.7193 in)Total thickness for the connecting rod bearing 1.805 - 1.815 mm (0.0710 - 0.0714 in)

Diameter of the small end with pressed and bored bushing 22.005 - 22.015 mm (0.8663 - 0.8667 in)Rough bushing thickness 1.7 - 1.8 mm (0.0669 - 0.0709 in)

Assembling the connecting rod

• Before installation, pay attention to ref-

erence marks and mounting direction.

• Reassemble the connecting rods on

the connecting rod pin in the crankshaft

seat and tighten the screws to the pre-

scribed torque.

CONNECTING ROD SHIMS CHECK

Check that the mounting clearance between con-

necting rod shims and crankshaft shoulders is

within the specified values: 0.265 - 0.515 mm

(0.0104 - 0.0203 in).


ENG - 138

Refitting the crankcase halves

• Insert the tappets after lubricating them

properly.

• Insert the camshaft into the seat in the

upper crankcase, lubricate and insert

locking the camshaft locking fitting.

• Insert the timing system side and fly-

wheel side half-bearings with their

thrust washers into the seats in the up-

per crankcase.


ENG - 139

• Insert the seal ring (after lubricating it)

on the crankshaft and the assembly

onto the engine crankcase making

sure that the connecting rods locate

correctly into their seats.


ENG - 140

• Fit the half-bearings (lubricate them

first) into the lower crankcase; apply

the specified liquid gasket to the crank-

case mating faces

• Join the two crankcase halves and tap

lightly with a mallet to ensure that the

two mating faces adhere together firm-

ly; tighten the four central stud bolts

and the external nuts following a criss-

cross pattern.


ENG - 141

Lubrication


1 Column nuts - 4 42 Nm (30.98 lbf ft) -2 Nut M8x1.25 6 22 Nm (16.22 lbf ft) -3 TCEI screw M6x25 12 10 Nm (7.37 lbf ft) -


ENG - 142

pos. Description Type Quantity Torque Notes4 Oil drainage plug M10x1 1 40 Nm (29.5 lbf ft) -- Spark plugs - 2 30 Nm (22.13 lbf ft) -

Oil pump

OIL PUMPpos. Description Type Quantity Torque Notes

1 Transmitter joint - 1 25 Nm (18.44 lbf ft) -2 Oil pressure sensor - 1 30 Nm (22.13 lbf ft) -3 Oil pump screws M6x35 3 10 Nm (7.38 lbf ft) Loctite 6484 Oil filter screw - 1 6 Nm (4.43 lbf ft) -

Removing

• After removing the timing system, re-

move the oil pump from the crankcase

unscrewing the Allen screws. Removal

procedure is as follows.


ENG - 143

• Remove the retaining key.

• Slide off the pump drive shaft with the

internal rotor attached.

• Slide off the external rotor.

• Slide off the bearings and their inner

housing from pump body.


ENG - 144

Inspection

OIL PUMP BODY

Check that the faces and inner seats of the oil

pump body are not scored, damaged or dented.

Pump body specifications

• External rotor seat Ø 40.650 - 40.675

mm (1.6004 - 1.6014 in);

• Pump drive shaft bore Ø 12.016 -

12.043 mm (0.4730 - 0.4741 in);

• Needle bearing seat Ø 21.972 - 21.993

mm (0.8650 - 0.8659 in);


ENG - 145

• External rotor seat thickness 15.030 -

15.070 mm (0.5917 - 0.5933 in).

EXTERNAL ROTOR

Check that the inner and outer surfaces and the

flat faces are not scored, damaged or dented; if

they are, replace both rotors.

External rotor specifications:

• outer Ø 40.540 - 40.570 mm (1.5960 -

1.5972 in);

• inner Ø 24.205 - 24.230 mm (0.9529 -

0.9539 in);

• thickness 14.960 - 14.990 mm (0.5890

- 0.5902 in).

INTERNAL ROTOR

Check that the inner and outer surfaces and the

flat faces are not scored, damaged or dented; if

they are, replace both rotors.

Internal rotor specifications:

• outer Ø 29.745 - 29.770 mm (1.1711 -

1.1720 in);

• inner Ø 12.000 - 12.018 mm (0.4724 -

0.4731 in);

• thickness 14.960 - 14.990 mm (0.5890

- 0.5902 in).

NEEDLE BEARINGS

Make sure the needle rollers of the bearings are

not damaged; if they are, replace the bearings.


ENG - 146

OIL PUMP DRIVE SHAFT

Check shaft and thread for damage; check the

keyway for burrs and make sure the head the runs

in the rotor is not damaged; replace the shaft if

needed.

Shaft specifications:

• Ø for pump body seat 11.982 - 12.000

mm (0.4717 - 0.4724 in);

• Ø for needle bearings 9.991 - 10.000

mm (0.3933 - 0.3937 in);

FITTING CLEARANCES

• between pump body and external rotor

0.080 - 0.135 mm (0.0031 - 0.0053 in);

• between internal rotor bore and drive

shaft 0.016 - 0.061 mm (0.0006 -

0.0024 in);

• between internal body bore and drive

shaft 0.016 - 0.061 mm (0.0006 -

0.0024 in);

Installing

• Assemble the oil pump and refit it to the

crankcase, paying attention to the two

alignment dowels.

• Tighten the Allen screws to the prescri-

bed torque and make sure the driving

shaft turns freely.


ENG - 147

Removing the oil sump

• Remove the engine oil filter.

• Unscrew the screws fixing the oil sump

to the engine crankcase, remove the oil

sump and the gasket.


ENG - 148

• Remove the oil level indicator.

• Straighten the safety plate, remove the

mesh filter retaining screw from the oil

sump and remove the mesh filter.

• Check that the mesh filter is not dirty, wash and blow with compressed air if needed.


ENG - 149

Refitting the oil sump

• Insert filter, safety plate and fixing

screw, then tighten the screw.

• Bend the safety plate.

• Position the gasket between the sump

and crankcase (always change the

gasket). Pay attention during the pro-

cedure; if wrongly installed, the gasket

will prevent proper oil circulation.


ENG - 150

• Tighten the sump screws following a

crisscross pattern to the prescribed tor-

que using a torque wrench.

• Insert the filter cartridge and tighten the

screw to the prescribed torque.

Pressure reducer valve

REMOVAL

• Unscrew the regulating valve mounted

on the threaded hole in the crankcase

using a suitable wrench.


ENG - 151

FITTING

• Insert the valve first and then the

spring, apply threadlocker to the screw

and tighten to the prescribed torque.


ENG - 152

AAlternator:

CChain: 113, 114Chain tensioner: 113, 114Clutch: 62, 65, 66, 86, 87, 89–92Crankcase: 130, 131, 135, 139Crankshaft: 130, 133, 136Cylinder: 96, 98, 104, 119, 120, 124–126

DDesmodromic drum: 65

EExhaust:

FForks: 66

HHead cover: 95, 97, 99, 128

OOil sump: 148, 150

PPrimary shaft: 44

SSecondary shaft: 51Starter motor: 85, 86

TThrottle body:

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